Engineering, Technology & Applied Science Research
3, 2022, 8482-8487 8482
The Importance of Accurate Boundary Condition in
Obtaining Reliable Shearing Stresses on a Torsional
Finite Element Simulation
Jairo Aparecido Martins
Research & Development
DESCH North America
Cambridge, Ontario, Canada
Jairo.martins@desch.com
Received: 21 December 2021 | Accepted: 3 January 2022
Abstract- Many combustion engines and electric motors drive
machines or equipment by turning a shaft and thus producing
work. As a relevant part of a machine principle, torque
transference deserves deep analysis regarding the techniques that
determine precisely the Finite Element (FE) boundary conditions
that are to be applied. This work presents a shaft loaded with a
torque that causes torsion and results in shear stresses in the
shaft material. In this context, when designing and calculating a
shaft to transfer torque, virtual analysis like FE Analysis (FEA)
must replicate the reality as accurately as possible. Indeed, slight
changes in load and constraint in a virtual simulation can
produce considerably different shear stresses and unrealistic
results. This paper aims to demonstrate how distinct boundary
conditions for the same torque transference can result in very
different results when a simulation does not comply with reality.
The results showed the importance of being very attentive when
applying loads and constraints on a shaft under torsion while
calculating it via FEA.
Keywords-torsion; numerical simulation; boundary conditions
I. INTRODUCTION
Finite Element Analysis (FEA) is becoming increasingly
popular among design engineers who use it as a product design
tool. Being safe and cost-efficient, the use of FEA as a product-
design tool requires training, practice, and, mainly, experience,
which is not present in the undergraduate curricula of
mechanical engineering programs due to time constraints [1-4].
Among applications and calculations by the tool, there are
many books on metallurgy and mechanics that describe many
types of loads and boundary conditions to consider, torque
being one among them as an important load.
Authors in [5-7] presented solid concepts and provided
examples of real applications for readers. In addition, there are
scientific works that calculate and analyze torque for several
interesting applications. Authors in [8] developed a FEA
program based on FORTRAN for analyzing working behavior
and calculating torque and drag during oil extraction. The
values of displacement obtained from the FEA model matched
those from the analytical model. Authors in [9] presented
Corresponding author: Estaner Claro Romão
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Vol. 12, No.
Estaner Claro Romão
Department of Environmental Engineering
Lorena School of Engineering, University of São Paulo
Lorena, São Paulo, Brasil
estaner23@usp.br
different methods for the calculation of torque as a function of
rotation angle in an electrical machine. The results obtained by
the distinct methodology were compared with the experimental
data, which allowed attaining practical information concerning
the advantages and limitations of each method. Authors in [10]
investigated techniques for the optimal design of permanent
magnet motors considering rotation. By applying the optimal
design method, the authors reduced about 40% of the volume
of the permanent magnet of the IPM motor and about 15% of
the torque ripple. This reinforced the idea that most of the FE
models should also be evaluated experimentally in order to be
calibrated with reality. However, even in a virtual simulation
platform, the model has to be as much realistic as possible and
should utilize the most accurate and realistic boundary
techniques. In this context, authors in [11] studied the
simplification of the design geometry in the FEA of structural
and other continuum problems and concluded that strategies for
identifying possible idealizations, controlling their application,
and estimating the associated errors appear to be feasible. In
particular, authors in [12] assessed the mechanical properties of
glass/metal joints. In his study, a Finite Element Method
(FEM) was implemented to analyze the torsional shear strength
test designed for glass-ceramic/steel joints aiming towards
solid oxide fuel/electrolysis cell application. The authors
concluded that the difference between the analytically derived
nominal shear strength, and the real critical shear stress derived
via simulation, reduces with decreasing fracture torque.
The boundary condition results might end up differently
and some of them wrong if the simulation is not as close to
reality as it could be. To the best of our knowledge, there are
no papers that describe the impacts on the results on FE
simulations when torque incurs on different (non-realistic)
boundary conditions. Many pieces of literature and videos on
media teach watchers how to run a FE simulation. However,
not always the presentations are correct and precise. For
instance, [13-15] described a few boundaries conditions for
torque application incompatible with reality and can cause
problems in the field. For this reason, this paper aims to
demonstrate how distinct boundary conditions for the same
 Engineering, Technology & Applied Science Research Vol. 12, No. 3, 2022, 8482-8487 8483

torque transference can result in expressively distinct results 

when a simulation does not comply with reality.
II. MATERIAL AND METHODS
This study used classical equations to determine the torque
to utilize in the FEM as a torsion load. The shaft used on the
simulations had one extreme constrained and another one
receiving a torsional momentum (torque). To calculate the
shearing stresses by numerical simulation, the shaft diameter
was kept fixed at 10mm, and the length changed throughout the
simulations. In addition, the loading region, where torque
incurred, was altered in the simulations, from face to partial
body, to whole body, and finally using an arm like if it were a
wrench. Two opposing torques (T) produce a twisting load
along the axis of a circular shaft, resulting in a total shear stress
distribution (τ) given by (1) [16]:
.
τ= (1)
 different ways. On the shaft face, along the shaft body, at a
where 0 ≤ r ≤ R. r is the distance from the center of the shaft
and R is the outside radius, both in mm. Since the diameter of
the shaft is fixed, therefore R.T is the applied torque (N.mm), τ
the shear stress (MPa), and J is the moment of polar inertia
(mm4), which is given by (2):
 =  . π. (2)
Therefore combining (1) to (2) results to:
. τ .π.
τ = π. or = (3)

Assuming a fixed shearing stress of 100MPa as well as a
fixed shaft diameter of 10mm, the torque result comes from (3)
and is fixed at 19,635N.mm. It is relevant to highlight that
since the purpose of the simulation is to apply 19,635N.mm as
a total torque, only half of the torque was input on the shaft
because the torque reaction generates the whole aimed torque.
The fixed torque value was used throughout all simulations
when running the FEA. In addition, each simulation had the
shaft length altered progressively from 10mm to 1,000mm. For
numerical simulations Autodesk F360 was utilized, considering
a linear-elastic analysis and as an output the von Mises stress
[18-20]. As seen in Table I, the same torque was input in four
particular region, and by applying a vertical force on the arm
attached to the shaft. In terms of mesh configuration, the same
mesh for all simulations was utilized, which followed a
maximum number of mesh refinement of 6, a convergence
tolerance of 5%, a portion (40%) of elements to refine it, and
an average element size of 10%.

TABLE I. BOUNDARY CONDITIONS FOR A SHAFT DIAMETER 10mm LOADED WITH A FIXED TORQUE OF 9,817.5N.mm.

Simulation boundaries Description

Shaft 10mm in diameter with length from 10 to 1,000mm.

Simulation with constraint at back surface and torque applied
on shaft face (SF).

Shaft 10mm in diameter with length from 10 to 1,000mm.

Simulation with constraint at the back surface and torque
applied on shaft whole body (SWB).

Shaft 10mm in diameter with length from 10 to 1,000mm.

Simulation with constraint at the back surface and a torque
applied on a body region of 15mm length (1.5 times the shaft
diameter) (SPB).

Shaft 10mm in diameter with length from 10 to 1,000mm.

Simulation with constraint at the back surface and force
applied on a wrench extreme (SWR).

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III. RESULTS AND DISCUSSION

Figures 1 to 4 show the different equivalent stress (von
Mises) in MPa for the following configurations: shaft with a
torque applied at its face (SF), shaft torque body (SWB), shaft
region (slip body) torque (SPB), and force with arm like a
wrench (SWR). Figure 1 shows the maximum stress at the edge
of the face where the torque is transmitted, and it reaches
105.1MPa for a shaft length of 60mm (SF). Figure 2 shows a
von Mises stress of 89.08MPa at constraint face.

Fig. 3. Example of a shaft (10mm diameter × 60mm) simulated with a

torque applied on a region of the body (SPB).

Fig. 1. Example of a shaft (10mm diameter × 60mm) simulated with a

torque applied on the face (SF).

SWB differed from the SF condition, from 105.1MPa to

89.08MPa. Not only the shear stress intensity was different, but
also the stress localization. Unlike SF, the maximum torque for
SWB moved to the opposite side from the torque load. Figure 3
shows a change in torque from SWB to SPB. At this case, the Fig. 4. Example of a shaft (10mm diameter × 60mm) simulated with a
maximum shearing stress was seen where the load was applied, force applied on arm (SWR).
and it reached 92.79MPa. When an arm was added (SWR),
then a force was applied to simulate the torque. The shearing Moreover, the standard deviation changes, depending on
stress reached 107.5MPa and was positioned close to the shaft the length. It begins from 28MPa for lengths between 10mm
constraint (Figure 4). Figure 5 shows the variance of shearing and 100mm and reduces to 14MPa for lengths between 100mm
stress for 10mm shaft diameter with a length changing from and 300mm and it ends up with 12MPa from lengths between
10mm to 1,000mm, and affixed torque of 9,817.5N.mm applied 300mm and 1,000mm.
on the shaft face (SF). For a short shaft (10mm length), the
stress was significantly higher than the calculated value of
100MPa, reaching a peak of 180MPa. The diameter and length
for this condition are the same and fixed at 10mm. There is a
wide stress variance and up and down change for lengths from
10 to 200mm when the stress decreases and reaches a value
close to the calculated value. However, after 200mm length, the
measured stress is unstable and has a high standard deviation as
seen in Table II and Figures 9 and 10.

Fig. 5. Shear stress with a torque applied on shaft face versus different
lengths (SF).

When stress is applied to the shaft body (SWB), it reaches

Fig. 2. Example of a shaft (10mm diameter × 60mm) simulated with a the highest stress level of 102MPa to a length of 10mm (Figure
torque applied on the body (SWB).

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6), thereafter it drops with length increment, reaching 86MPa
when the length is 30mm. Soon after this point, the stress starts
increasing again and it reaches 95MPa for a length maximum
of 1,000mm. The standard deviation changes from 4MPa for
lengths between 10mm and 100mm, then it reduces to 1MPa
for lengths between 100mm and 300mm and ends up at 1MPa
for lengths between 300mm and 1,000mm.
Fig. 6. Shear stress with a torque applied on shaft body versus different
lengths (SWB).
When the torque is loaded on a specific and limited region
of the shaft (SPB), the stress starts with a high value for a short
shaft (103MPa for 10mm length), then it drops to 93MPa,
thereon stresses fluctuate up and down and reach 95MPa at
1,000mm length (Figure 7). When it comes to standard
deviation, it changes from 3MPa for lengths between 10mm
and 100mm, then it reduces to 1MPa for lengths between
100mm and 300mm, and ends up at 1MPa for lengths between
300mm and 1,000mm. This presents a quite similar standard
deviation when compared with the previous condition (SWB).
Fig. 7. Shear stress with a torque applied on shaft specific region versus
different length (SPB).
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Vol. 12, No. 3, 2022, 8482-8487 8485
A distinct behavior from previous situations is verified for a
shaft that has an arm with a force-generating a torque (SWR) as
shown in Figure 8. The shearing stress is pretty close to
100MPa as previously calculated analytically, but for 120mm
and onwards it raises continually and moderately until 300mm
when there is a steep inclination on the graph, demonstrating a
mechanical instability. The standard deviation changes from
2MPa for lengths between 10mm and 100mm, then it goes up
to 15MPa for lengths between 100mm and 300mm and it
steeped up considerably to 89MPa for lengths between 300mm
and 1,000mm. This presents the highest instability of all
previous conditions. This stability comes from a lack of rigidity
of the bar when it gets longer and longer until a point where the
combination becomes totally mechanically unstable (uneven).
Fig. 8. Shear stress with a torque applied on shaft by a force applied on an
arm (SWR).
Table II shows the partial calculations of shearing stress
averages and standard deviations. It compiles variations of von
Mises stress average and how data deviation occurs based on
standard deviation. The shaft with a torque applied on a
specific region showed the closer value to the calculated
100MPa (95MPa) and the lower standard deviation throughout
all shaft lengths. In Figures 9 and 10, there is a comparison
among stresses generated by torques applied on a region of a
shaft body. A line at 100MPa is traced to help compare FEA to
the analytical calculated value. The condition where the torque
is applied on the face of the bar (Figure 9 left) shows that for
short bars, the von Mises stress is higher, then it decreases
constantly until the length of 1,000mm, which is 100 times the
diameter of the shaft.
Therefore, this condition shows stress values that, when
compared with the analytical calculation, do not seem accurate
enough or reliable. When the torque is applied on the whole
body (Figure 9(b)), the von Mises values are similar, and close
to 90MPa for the full range of lengths with a standard value
very low for short shafts as well as for longer bars. This means
that the stress value is only 10% lower than the analytical
calculated von Mises stress. When the torque is applied on a
specific region of the bar, established as 1.5 times the shaft
diameter (Figure 10(a)), the stress values were very close to the
analytical calculation and varied from 95 to 96MPa.
 Engineering, Technology & Applied Science Research Vol. 12, No. 3, 2022, 8482-8487 8486

TABLE II. DISTINCT VALUES FOR EACH CONFIGURATION

Von Mises stress Calculated stress (τ) Von Mises stress

Calculated stress (τ) Von Mises (MPa) Calculated stress (τ)
(MPa) (MPa) (MPa)
Condition (MPa) StDev Average (MPa) StDev
Average StDev Average
100 ≤ L ≤ 300 300 ≤ L ≤ 1,000 300 ≤ L ≤ 1,000
10 ≤ L ≤ 100 10 ≤ L ≤ 100 100 ≤ L ≤ 300
SF 145 28 125 14 115 12
SWB 90 4 91 1 95 1
SPB 95 3 94 1 96 1
SWR 95 2 117 15 276 89

2MPa. The second was the SPB condition, with also 95MPa for
shear stress and a standard deviation of 3MPa. The third
condition was SWB, with an average of 90MPa and a standard
deviation of 4MPa, and the last one was SF with an average of
145MPa and standard deviation of 28MPa, see Table II and
Figures 9 and 10.

(a)

(a)

(b)

(b)

Fig. 9. (a) Torques and standard deviation from distinct length intervals
for (a) SF, (b) SWB.

This configuration represents remarkably real conditions

seen on machines and equipment where an electrical motor has
a coupling assembled on a specific length of the shaft. The final
configuration applied a torque indirectly on the shaft by using
an arm. At the extreme of the arm, the force that generates the
torque was applied. At this case, the value was very close to the
analytical one (100MPa analytical value versus 95MPa for
simulation) for short shafts smaller than 100mm. For shafts
with lengths between 100mm and 300mm the value surpassed
the analytical value (117MPa versus 100MPa) and reached
276MPa, which is completely unrealistic.
The configurations were ranked comparatively with the
analytical calculation. The closer value was verified at the
SWR condition, to shaft length from 10 to 100mm, presenting
a shear stress average of 95MPa and a standard deviation of
Fig. 10. Torques and standard deviation from distinct length intervals for
(a) torque applied on a specific region of the shaft (SPB), (b) torque inputted
on an arm like a wrench (SWR).
For shaft's lengths from 100 to 300mm, the sequence
changed. The SPB condition ranked first with a von Mises
Stress of 94MPa and standard deviation of 1MPa, the second
was SWB with a von Mises Stress of 91MPa and standard
deviation of 1MPa. SWR was the third with a von Mises Stress
of 117MPa and standard deviation of 15MPa, and SF was last
exhibiting a von Mises Stress of 125MPa and standard
deviation of 14MPa. For longer lengths (300 to 1,000mm) there
was another change in positions. First was SPB with a von
Mises Stress of 96MPa and standard deviation of 1MPa, then

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 Engineering, Technology & Applied Science Research Vol. 12, No. 3, 2022, 8482-8487 8487

SWB with a von Mises Stress of 95MPa and standard deviation [10] T. Ohnishi and N. Takahashi, "Optimal design of efficient IPM motor
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ACKNOWLEDGMENT Coordinates by Fourth-Order FDM," Engineering, Technology &
Applied Science Research, vol. 8, no. 1, pp. 2389–2392, Feb. 2018,
The authors acknowledge the financial support by CAPES https://doi.org/10.48084/etasr.1724.
(process number 23038.000263/2022-19).
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